Instruction Manual. Designed for Elevating Machinery. Fuji Electric FA Components & Systems Co., Ltd.

Transcription

1 Instruction Manual Designed for Elevating Machinery Thank you for purchasing our FRENIC-Lift series of inverters. This product is designed to drive a three-phase induction motor and synchronous motor. Read through this instruction manual and be familiar with the handling procedure for correct use. Improper handling might result in incorrect operation, a short life, or even a failure of this product as well as the motor. Deliver this manual to the end user of this product. Keep this manual in a safe place until this product is discarded. For how to use an option card, refer to the installation and instruction manuals for that option card. Fuji Electric FA Components & Systems Co., Ltd. INR-SI a-E

2 Copyright 2005 Fuji Electric FA Components & Systems Co., Ltd. All rights reserved. No part of this publication may be reproduced or copied without prior written permission from Fuji Electric FA Components & Systems Co., Ltd. All products and company names mentioned in this manual are trademarks or registered trademarks of their respective holders. The information contained herein is subject to change without prior notice for improvement.

3 Preface Thank you for purchasing our FRENIC-Lift series of inverters. FRENIC-Lift is an inverter designed to drive a three-phase induction motor (hereafter called an induction motor) and a three-phase permanent magnet synchronous motor (hereafter called a synchronous motor) for exclusively controlling elevating machinery. Improper handling might result in incorrect operation, a short life, or even a failure of this product as well as the motor. To drive a synchronous motor, a PG interface card option involving a pulse encoder is needed. For derails, refer to the instruction manual of PG Interface Card. Listed below are the other materials related to the use of the FRENIC-Lift. Read them in conjunction with this manual as necessary. Multi-function Keypad "TP-G1-CLS" Instruction Manual (INR-SI E) FRENIC-Lift Reference Manual (INR-SI E) The materials are subject to change without notice. Be sure to obtain the latest editions for use. Safety precautions Read this manual thoroughly before proceeding with installation, connections (wiring), operation, or maintenance and inspection. Ensure you have sound knowledge of the device and familiarize yourself with all safety information and precautions before proceeding to operate the inverter. Safety precautions are classified into the following two categories in this manual. Failure to heed the information indicated by this symbol may lead to dangerous conditions, possibly resulting in death or serious bodily injuries. Failure to heed the information indicated by this symbol may lead to dangerous conditions, possibly resulting in minor or light bodily injuries and/or substantial property damage. Failure to heed the information contained under the CAUTION title can also result in serious consequences. These safety precautions are of utmost importance and must be observed at all times. Application FRENIC-Lift is equipment designed to drive induction motors and synchronous motors for exclusively controlling elevating machinery. Do not use it for single-phase motors or for other purposes. Fire or accident could occur. FRENIC-Lift may not be used for a life-support system or other purposes directly related to the human safety. Though FRENIC-Lift is manufactured under strict quality control, install safety devices for applications where serious accidents or material losses are foreseen in relation to the failure of it. An accident could occur. i

4 Installation Install the inverter on a nonflammable material such as metal. Otherwise fire could occur. Do not place flammable matter nearby. Doing so could cause fire. Using an optional DC reactor makes human body easily touch any live parts of inverters. In this case, take countermeasures such as installing the inverter in a place that easily protects human body from electric shock. Otherwise, electric shock or injuries could occur. Do not support the inverter by its terminal block cover during transportation. Doing so could cause a drop of the inverter and injuries. Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into the inverter or from accumulating on the heat sink. Otherwise, a fire or an accident might result. Do not install or operate an inverter that is damaged or lacking parts. Doing so could cause fire, an accident or injuries. Do not get on a shipping box. Do not stack shipping boxes higher than the indicated information printed on those boxes. Doing so could cause injuries. Wiring When wiring the inverter to the power source, insert a recommended molded case circuit breaker (MCCB) or residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) (with overcurrent protection) in the path of power lines. Use the devices within the recommended current range. Use wires in the specified size. Otherwise, fire could occur. Do not use one multicore cable in order to connect several inverters with motors. Do not connect a surge killer to the inverter's output (secondary) circuit. Doing so could cause fire. Install inverters in compliance with the local regulation. Otherwise, electric shock or fire could occur. Qualified electricians should carry out wiring. Be sure to perform wiring after turning the power OFF. Otherwise, electric shock could occur. Be sure to perform wiring after installing the inverter body. Otherwise, electric shock or injuries could occur. ii

5 Ensure that the number of input phases and the rated voltage of the product match the number of phases and the voltage of the AC power supply to which the product is to be connected. Otherwise fire or an accident could occur. Do not connect the power source wires to output terminals (U, V, and W). Doing so could cause fire or an accident. Generally, control signal wires are not enforced- insulated. If they accidentally touch any live power lines, their insulation coat may break for any reasons. In such a case, an extremely high voltage may be applied to the signal lines. Make a complete remedy to protect the signal line from contacting any live high voltage lines. Otherwise, an accident or electric shock could occur. Wire the three-phase motor to terminals U, V, and W of the inverter, aligning phases each other. Otherwise injuries could occur. The inverter, motor and wiring generate electric noise. Take care of malfunction of the nearby sensors and devices. To prevent the motor from malfunctioning, implement noise control measures. Otherwise an accident could occur. Operation Be sure to install the terminal block cover and the front cover before turning the power ON. Do not remove the covers while power is applied. Otherwise electric shock could occur. Do not operate switches with wet hands. Doing so could cause electric shock. If the retry function has been selected, the inverter may automatically restart and drive the motor depending on the cause of tripping. (Design the machinery or equipment so that human safety is ensured after restarting.) If the stall prevention function (current limiter), automatic deceleration, and overload prevention control have been selected, the inverter may operate at an acceleration/deceleration time or frequency different from the commanded ones. Design the machine so that safety is ensured even in such cases. Otherwise an accident could occur. If an alarm reset is made with the Run command signal turned ON, a sudden start will occur. Ensure that the Run command signal is turned OFF in advance. Otherwise an accident could occur. If you set the function codes wrongly or without completely understanding this instruction manual and the FRENIC-Lift Reference Manual (INR-SI E), the motor may rotate with a torque or at a speed not permitted for the machine. In the tuning process of the inverter, no motor torque control for braking of the machinery takes effect. Tune the inverter for the motor after disconnecting it from the machinery, or after mechanically brakes the machinery. Anyway, do it after suppressing any dangerous factors. An accident or injuries could occur. Do not touch the inverter terminals while the power is applied to the inverter even if the inverter stops. Doing so could cause electric shock. iii

6 Do not turn the main circuit power (circuit breaker) ON or OFF in order to start or stop inverter operation. Doing so could cause failure. Do not touch the heat sink because they become very hot. Doing so could cause burns. Setting the inverter to high speeds is easy. Before changing the frequency (speed) setting, check the specifications of the motor and machinery. The brake function of the inverter does not provide mechanical holding means. Injuries could occur. Setting control switches Before setting up any internal control switches, turn OFF the power, and wait for more than five minutes. Further, check that the LED monitor is unlit, and make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P (+) and N (-) has dropped below a safe voltage (+25 VDC). Otherwise electric shock could occur. Maintenance and inspection, and parts replacement Turn the power OFF and wait for more than five minutes, before starting inspection. Further, check that the LED monitor is unlit, and check the DC link bus voltage between the P (+) and N (-) terminals to be lower than 25 VDC. Otherwise, electric shock could occur. Maintenance, inspection, and parts replacement should be made only by qualified persons. Take off the watch, rings and other metallic matter before starting work. Use insulated tools. Otherwise, electric shock or injuries could occur. Disposal Handle the inverter as an industrial waste when disposing of it. Otherwise injuries could occur. Others Never attempt to modify the inverter. Doing so could cause electric shock or injuries. GENERAL PRECAUTIONS Drawings in this manual may be illustrated without covers or safety shields for explanation of detail parts. Restore the covers and shields in the original state and observe the description in the manual before starting operation. iv

7 Precautions for use In running generalpurpose motors In running special motors Environmental conditions Driving a 400V general-purpose motor Torque characteristics and temperature rise Vibration Noise Brake motors Geared motors Single-phase motors Installation location When driving a 400V general-purpose motor with an inverter using extremely long wires, damage to the insulation of the motor may occur. Apply the inverter after consulting the motor maker. When the inverter is used to run a general-purpose motor, the temperature of the motor becomes higher than when it is operated using a commercial power supply. In the low-speed range, the cooling effect will be weakened, so decrease the output torque of the motor. When an inverter-driven motor is mounted to a machine, resonance may be caused by the natural frequencies of the machine system. Note that operation of a 2-pole motor at 60 Hz or higher may cause abnormal vibration. * The use of a rubber coupling or vibration dampening rubber is recommended. * Run your machinery including FRENIC-Lift inverter so as to skip its resonance frequency zone/s. When an inverter is used with a general-purpose motor, the motor noise level is higher than that with a commercial power supply. To reduce noise, raise carrier frequency of the inverter. Operation at 60 Hz or higher can also result in higher noise level. For motors equipped with parallel-connected brakes, their braking power must be supplied from the primary circuit. If the brake power is connected to the inverter's output circuit by mistake, the brake will not work. Do not use inverters for driving motors equipped with series-connected brakes. If the power transmission mechanism uses an oil-lubricated gearbox or speed changer/reducer, then continuous motor operation at low speed may cause poor lubrication. Avoid such operation. Single-phase motors are not suitable for inverter-driven variable speed operation. Use three-phase motors. Use the inverter within the ambient temperature range from -10 to +45 C. The heat sink and braking resistor of the inverter may become hot under certain operating conditions, so install the inverter on nonflammable material such as metal. Ensure that the installation location meets the environmental conditions specified in Chapter 2, Section 2.1 "Operating Environment." v

8 Combination with peripheral devices Wiring Installing an MCCB or RCD/ELCB Installing an MC in the secondary circuit Installing an MC in the primary circuit Protecting the motor Discontinuance of power-factor correcting capacitor Discontinuance of surge killer Reducing noise Measures against surge currents Megger test Control circuit wiring length Wiring length between inverter and motor Wiring size Wiring type Grounding Install a recommended molded case circuit breaker (MCCB) or residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) (with overcurrent protection) in the primary circuit of the inverter to protect the wiring. Ensure that the circuit breaker capacity is equivalent to or lower than the recommended capacity. If a magnetic contactor (MC) is mounted in the inverter's output (secondary) circuit, ensure that both the inverter and the motor are completely stopped before you turn the MC on or off. Remove a surge killer built-in the MC. Do not turn the magnetic contactor (MC) in the primary circuit ON or OFF more than once an hour as an inverter failure may result. If frequent starts or stops are required during motor operation, use FWD / REV signals. The electronic thermal function of the inverter can protect the motor. The operation level and the motor type (general-purpose motor, inverter motor) should be set. For high-speed motors or water-cooled motors, set a small value for the thermal time constant and protect the motor. If you connect the motor thermal relay to the motor with a long wire, a high-frequency current may flow into the wiring stray capacitance. This may cause the relay to trip at a current lower than the set value for the thermal relay. If this happens, lower the carrier frequency. Do not mount power-factor correcting capacitors in the inverter s primary circuit. (Use the DC reactor to improve the inverter power factor.) Do not use power-factor correcting capacitors in the inverter s output (secondary) circuit. An overcurrent trip will occur, disabling motor operation. Do not connect a surge killer to the inverter's output (secondary) circuit. Use of a filter and shielded wires is typically recommended to satisfy EMC Directives. If an overvoltage trip occurs while the inverter is stopped or operated under a light load, it is assumed that the surge current is generated by open/close of the phase-advancing capacitor in the power system. * Connect a DC reactor to the inverter. When checking the insulation resistance of the inverter, use a 500 V megger and follow the instructions contained in Chapter 7, Section 7.5 "Insulation Test." When using remote control, limit the wiring length between the inverter and operator box to 20 m or less and use twisted pair or shielded wire. If long wiring is used between the inverter and the motor, the inverter will overheat or trip as a result of overcurrent (high-frequency current flowing into the stray capacitance) in the wires connected to the phases. Ensure that the wiring is shorter than 20 m. If this length must be exceeded, lower the carrier frequency. Select wires with a sufficient capacity by referring to the current value or recommended wire size. When several inverters drive motors, do not use one multicore cable in order to connect several inverters with motors. Securely ground the inverter using the grounding terminal. vi

9 Selecting inverter capacity Transportation and storage Driving general-purpose motor Driving special motors Select an inverter according to the applicable motor ratings listed in the standard specifications table for the inverter. When high starting torque is required or quick acceleration or deceleration is required, select an inverter with a capacity one size greater than the standard. Select an inverter that meets the following condition: Inverter rated current > Motor rated current When transporting or storing inverters, follow the procedures and select locations that meet the environmental conditions listed in Chapter 1, Section 1.3 "Transportation" and Section 1.4 "Storage Environment." vii

10 How this manual is organized This manual is made up of chapters 1 through 9. Chapter 1 BEFORE USING THE INVERTER This chapter describes acceptance inspection and precautions for transportation and storage of the inverter. Chapter 2 MOUNTING AND WIRING OF THE INVERTER This chapter provides operating environment, precautions for installing the inverter, wiring instructions for the motor and inverter. Chapter 3 OPERATION USING THE KEYPAD The FRENIC-Lift has no standard keypad. Operating the FRENIC-Lift from a keypad requires an optional multi-function keypad. For details in operations, refer to the Multi-function Keypad "TP-G1-CLS" Instruction Manual (INR-S E). Chapter 4 RUNNING THE MOTOR This chapter describes preparation to be made before running the motor for a test and practical operation. Chapter 5 FUNCTION CODES This chapter provides a list of the function codes. For details of function codes, refer to the FRENIC-Lift Reference Manual (INR-S E.) Chapter 6 TROUBLESHOOTING This chapter describes troubleshooting procedures to be followed when the inverter malfunctions or detects an alarm condition. In this chapter, first check whether any alarm code is displayed or not, and then proceed to the troubleshooting items. Chapter 7 MAINTENANCE AND INSPECTION This chapter describes inspection, measurement and insulation test which are required for safe inverter operation. It also provides information about periodical replacement parts and guarantee of the product. Chapter 8 SPECIFICATIONS This chapter lists specifications including output ratings, control system, external dimensions and protective functions. Chapter 9 LIST OF PERIPHERAL EQUIPMENT AND OPTIONS This chapter describes main peripheral equipment and options which can be connected to the FRENIC-Lift series of inverters. Icons The following icons are used throughout this manual. This icon indicates information which, if not heeded, can result in the inverter not operating to full efficiency, as well as information concerning incorrect operations and settings which can result in accidents. This icon indicates information that can prove handy when performing certain settings or operations. This icon indicates a reference to more detailed information. viii

11 Table of Contents Preface...i Safety precautions...i Precautions for use...v How this manual is organized...viii Chapter 1 BEFORE USING THE INVERTER Acceptance Inspection External View and Terminal Blocks Transportation Storage Environment Temporary storage Long-term storage Chapter 2 MOUNTING AND WIRING OF THE INVERTER Operating Environment Installing the Inverter Wiring Removing and mounting the terminal block (TB) cover and the front cover Removing and retracting the cable guide plate Terminal arrangement and screw specifications Recommended wire sizes Wiring precautions Wiring for main circuit terminals and grounding terminals Wiring for control circuit terminals Setting up slide switches Cautions Relating to Harmonic Component, Noise, and Leakage Current Chapter 3 OPERATION USING THE KEYPAD Chapter 4 RUNNING THE MOTOR Running the Motor for a Test Inspection and preparation prior to powering on Turning ON power and checking Preparation before running the motor for a test--setting function code data Test run Operation Chapter 5 FUNCTION CODES Function Code Tables Chapter 6 TROUBLESHOOTING Before Proceeding with Troubleshooting If No Alarm Code Appears on the LED Monitor Motor is running abnormally Problems with inverter settings If an Alarm Code Appears on the LED Monitor If an Abnormal Pattern Appears on the LED Monitor while No Alarm Code is Displayed Chapter 7 MAINTENANCE AND INSPECTION Daily Inspection Periodic Inspection List of Periodical Replacement Parts Judgment on service life Measurement of Electrical Amounts in Main Circuit Insulation Test Inquiries about Product and Guarantee Chapter 8 SPECIFICATIONS Standard Models Common Specifications Terminal Specifications Terminal functions In case of operation per external signal input External Dimensions Standard models Protection Features Chapter 9 LIST OF PERIPHERAL EQUIPMENT AND OPTIONS ix

12 Chapter 1 BEFORE USING THE INVERTER 1.1 Acceptance Inspection Unpack the package and check that: (1) An inverter and accessories below are contained in the package. Cooling fan mounting screws (5.5 to 22 kw) Rubber bushes for cable guide plate (5.5 to 22 kw) An instruction manual (this manual) (2) The inverter has not been damaged during transportation there should be no dents or parts missing. (3) The inverter is the model you ordered. You can check the model name and specifications on the main nameplate. (Main and sub nameplates are attached to the inverter and are located as shown on the following page.) For the inverter whose capacity is 37 kw or above, the mass of that is printed on the nameplate. TYPE SER.No. FRN15LM1S-4C 4Z3710K1208 TYPE: Inverter model (a) Main Nameplate Figure 1.1 Nameplates (b) Sub Nameplate Code Series name FRN FRENIC series Code Applocation motor rating kw kw kw kw kw kw Code Applicable area LM Elevating machinery F R N 5. 5 L M 1 S - 4 C Code Shipping destination/ Instruction manual version C China/Chinese E EU/English A Asia/English Code Power supply voltage 4 Three-phase 400 V Code Enclosure S Standard (IP20) Code Development code 1 1 SOURCE: OUTPUT: SER. No.: Number of input phases (three-phase: 3PH), input voltage, input frequency, input current Number of output phases, rated output capacity, rated output voltage, output frequency range, rated output current, overload capacity Product number 4 Z K Serial number of production lot Production month 1 to 9: January to September X, Y, or Z: October, November, or December Production year: Last digit of year If you suspect the product is not working properly or if you have any questions about your product, contact your Fuji Electric representative. 1-1

13 1.2 External View and Terminal Blocks (1) Outside and terminal block views Terminal block cover Cooling fans Dummy cover Front cover Cable guide plate Warning plate Screw Main nameplate Main circuit Terminal block cover terminal block Figure 1.2 Outside and Terminal Block Views of Inverters Control circuit terminal block (2) Warning plates Figure 1.3 Warning Plates (3) Terminal block location Main circuit terminal block Control circuit terminal block Figure 1.4 Main and Control Circuit Terminal Block Location 1-2

14 1.3 Transportation When carrying an inverter, always support its bottom at the front and rear sides with both hands. Do not hold covers or individual parts only. You may drop the inverter or break it. 1.4 Storage Environment Temporary storage Store the inverter in an environment that satisfies the requirements listed in Table 1.1. Table 1.1 Environmental Requirements for Storage and Transportation Item Requirements Storage temperature * 1-25 to +65 C A location where the inverter is not subject to abrupt changes in Relative humidity 5 to 95% * 2 temperature that would result in the formation of condensation or ice. Atmosphere The inverter must not be exposed to dust, direct sunlight, corrosive or flammable gases, oil mist, vapor, water drops or vibration. The atmosphere must contain only a low level of salt. (0.01 mg/cm 2 or less per year) Atmospheric pressure 86 to 106 kpa (in storage) 70 to 106 kpa (during transportation) * 1 Assuming a comparatively short storage period (e.g., during transportation or the like). * 2 Even if the humidity is within the specified requirements, avoid such places where the inverter will be subjected to sudden changes in temperature that will cause condensation to form. Precautions for temporary storage (1) Do not leave the inverter directly on the floor. (2) If the environment does not satisfy the specified requirements, wrap the inverter in an airtight vinyl sheet or the like for storage. (3) If the inverter is to be stored in an environment with a high level of humidity, put a drying agent (such as silica gel) in the airtight package described in item (2) Long-term storage The long-term storage methods for the inverter vary largely according to the environment of the storage site. General storage methods are described below. (1) The storage site must satisfy the requirements specified for temporary storage. However, for storage exceeding three months, the ambient temperature should be within the range from -10 to +30 C. This is to prevent the electrolytic capacitors in the inverter from deteriorating. (2) The inverter must be stored in a package that is airtight to protect it from moisture. Include a drying agent inside the package to maintain the relative humidity inside the package to within 70%. (3) If the inverter has been installed in the equipment or control board at a construction site where it may be subjected to humidity, dust or dirt, then remove the inverter and store it in a suitable environment specified in Table 1.1. Precautions for storage over 1 year If the inverter will not be powered on for a long time, the property of the electrolytic capacitors may deteriorate. Power the inverters on once a year and keep them on for 30 to 60 minutes. Do not connect the inverters to motors or run the motor. 1-3

15 Chapter 2 MOUNTING AND WIRING OF THE INVERTER 2.1 Operating Environment Install the inverter in an environment that satisfies the requirements listed in Table 2.1. Table 2.1 Environmental Requirements Table 2.2 Output Current Derating Factor in Relation to Altitude Item Specifications Site location Indoors Altitude Output current derating factor Ambient -10 to +45 C 1000 m or lower 1.00 temperature Relative humidity 5 to 95% (No condensation) 1000 to 1500 m 1500 to 2000 m Atmosphere The inverter must not be exposed to dust, direct sunlight, corrosive gases, flammable gas, oil mist, vapor or water drops. (Note 1) The atmosphere must contain only a low level of salt. (0.01 mg/cm 2 or less per year) The inverter must not be subjected to sudden changes in temperature that will cause condensation to form. Altitude 1,000 m max. (Note 2) Atmospheric pressure Vibration 86 to 106 kpa 2.2 Installing the Inverter 3 mm (Max. amplitude) 2 to less than 9 Hz 9.8 m/s 2 9 to less than 20 Hz 2 m/s 2 20 to less than 55 Hz 1 m/s 2 55 to less than 200 Hz 2000 to 2500 m to 3000 m 0.88 (Note 1) Do not install the inverter in an environment where it may be exposed to cotton waste or moist dust or dirt which will clog the heat sink in the inverter. If the inverter is to be used in such an environment, install it in the enclosure of your system or other dustproof containers. (Note 2) If you use the inverter in an altitude above 1000 m, you should apply an output current derating factor as listed in Table 2.2. (1) Mounting base The temperature of the heat sink will rise up to approx. 90 C during operation of the inverter, so the inverter should be mounted on a base made of material that can withstand temperatures of this level. Top 100 mm Install the inverter on a base constructed from metal or other non-flammable material. A fire may result with other material. Left 10 mm Right 10 mm (2) Clearances Ensure that the minimum clearances indicated in Figure 2.1 are maintained at all times. When installing the inverter in the enclosure of your system, take extra care with ventilation inside the enclosure as the temperature around the inverter will tend to increase. Do not install the inverter in a small enclosure with poor ventilation. Further, do not install two or more inverters in single equipment or in an enclosure. Bottom 100 mm Figure 2.1 Mounting Direction and Required Clearances 2-1

16 When employing external cooling As factory shipment, the cooling unit will be placed inside your equipment or enclosure so that cooling is done all internally. To improve cooling efficiency, you can take the heat sink cooling unit out of the inverter s enclosure or the equipment (as shown on the right) so that cooling is done both internally and externally (this is called external cooling ). In external cooling, the heat sink, which removes about 70% of the total heat dissipation (total loss generated) into air, is situated outside the equipment or the enclosure. As a result, much less heat is radiated inside the inverter. To take advantage of external cooling, you need to use the external cooling attachment option for inverters. Do not, however, use external cooling (take the cooling unit half way out of the inverter or the control panel) in an environment with high humidity or a lot of fibrous dust, which tends to clog the heat sink. For details, refer to the Mounting Adapter for External Cooling "PB-F1" Installation Manual (INR-SI ). Figure 2.2 External Cooling Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into the inverter or from accumulating on the heat sink. This may result in a fire or accident. 2-2

17 (3) Mounting direction Horizontal layout is recommended when two or more inverters are to be installed in an equipment or enclosure. As long as the ambient temperature is 40 C or lower, inverters may be mounted side-by-side without any gap between them. If it is necessary to mount the inverters vertically, install a partition plate or the like between the inverters so that any heat radiating from an inverter will not affect the one/s above. Do not mount the inverter upside down or horizontally. Doing so will reduce the heat dissipation efficiency of the inverter and cause the overheat protection function to operate, so the inverter will not run. (4) Solving abnormal vibration after installation If any vibration in the surroundings reaches the inverter and causes abnormal vibration to the cooling fan(s) or the keypad, fix them firmly using the fixing screws provided as accessories. Fixing the cooling fan(s) Power supply voltage Threephase 400 V Applicable motor rating (kw) Table 2.3 Fixing Screws Inverter type 5.5 FRN5.5LM1S FRN7.5LM1S-4 11 FRN11LM1S-4 15 FRN15LM1S FRN18.5LM1S-4 22 FRN22LM1S-4 Screw size (accessory) Tightening torque (N m) Refer to: M4x35 (4 pcs) 0.8 Figure A M4x50 (2 pcs) 0.8 Figure B Note A box ( ) in the above table replaces C, E or A depending on the shipping destination. Attached screws Attached screws Cooling fans Cooling fans Figure A Figure 2.3 Figure B Fixing the Cooling Fan(s) 2-3

18 2.3 Wiring Follow the procedure below. (In the following description, the inverter has already been installed.) Removing and mounting the terminal block (TB) cover and the front cover Removing the covers 1) To remove the TB cover, loosen the fastening screw on it, hold the dimple (labeled PULL ), and pull it up toward you. 2) To remove the front cover, hold it with both hands, slide it downward, disengage the latch at the top from the inverter, tilt the front cover toward you, and pull it upward. Terminal block cover Terminal block cover fastening screw "PULL" mark Front cover Figure 2.4 Removing the Covers 2-4

19 Mounting the covers Put the front cover to the inverter case so that its bottom engages with the hinges provided on both sides of the case. Push the front cover against the case of the inverter and slide it upward until the latch at its top engages with the case. Mount the TB cover onto the case of the inverter so that the latch at the top of the TB cover engages with a hole provided at the bottom of the front cover. Tighten the screw on the TB cover (Tightening torque: 1.8 N m). Front cover Front cover Hinge View from Front cover Hole Hole Latch Terminal block cover View from Latch Cover fastening screw (terminal block cover) Terminal block cover Figure 2.5 Mounting the Covers 2-5

20 2.3.2 Removing and retracting the cable guide plate To secure the protective structure IP20, FRENIC-Lift builds in the cable guide plate for external wiring connections. To use it follow the steps listed below. Removing the cable guide plate Before to proceed, remove the terminal block cover as shown below left. Loosen and remove the screw fastening the cable guide plate, and pull the plate remove. Cable guide plate Cable guide plate fastening screw Figure 2.6 Removing the Cable Guide Plate Opening half-punched holes and mounting rubber bushes Tap an inside face of the half-punched hole by using a screwdriver grip end or the like to punch it out. Punch out all 3 holes. Be careful not to injure yourself by sharp cutting edges of parts. Set 3 attached rubber bushes in the holes and cut in them by a cutting tool to make cut-outs as shown below. All cables of an inverter should pass through any of cut-outs Half-punched holes Cable guide plate Figure 2.7 Attached rubber bushes Punching out the Holes and Mounting the Rubber Bushes Cut-outs Be sure to use the rubber bushes. If not, a sharp cutting edge of the cable guide plate hole may damage the cable sheath. This may induce a short-circuit fault or ground fault. A fire or an accident may be caused. Retracting the cable guide plate Retract the cable guide plate following the steps illustrated in Figure 2.6 in reverse. (Tightening torque: 1.8 N m) 2-6

21 2.3.3 Terminal arrangement and screw specifications The figures below show the arrangement of the main and control circuit terminals which differs according to inverter type. The two terminals prepared for grounding, which are indicated by the symbol G in Figures A to J, make no distinction between the power supply side (primary circuit) and the motor side (secondary circuit). (1) Arrangement of the main circuit terminals Table 2.4 Main Circuit Terminals Power supply voltage Threephase 400 V Applicable motor rating (kw) Inverter type 5.5 FRN5.5LM1S FRN7.5LM1S-4 11 FRN11LM1S-4 15 FRN15LM1S FRN18.5LM1S-4 22 FRN22LM1S-4 Terminal screw size Tightening torque (N m) Grounding screw size Tightening torque (N m) M5 3.8 M5 3.8 M6 5.8 M6 5.8 Terminal R0, T0 (Common to all types): Screw size M3.5, Tightening torque 1.2 (N m) Note A box ( ) in the above table replaces C, E or A depending on the shipping destination. Refer to: Figure A Figure B Terminal board illustrated in Figure B has a two-tired structure. Take an attention for this structure to connect wires to main input (primary) output (secondary) terminals. 2-7

22 (2) The control circuit terminals (common to all models) Screw size: M3 Tightening torque: 0.5 to 0.7 (N m) Screw size: M2 Tightening torque: 0.22 to 0.25 (N m) Table 2.5 Control Circuit Terminals Terminal group Screwdriver to be used (Head style) Allowable wire size Bared wire length Dimension of openings in the control circuit terminals for post terminals* A Flat head (0.6 mm x 3.5 mm) AWG26 to AWG16 (0.14 to 1.5 mm 2 ) 6 mm 2.51 mm (W) x 1.76 mm (H) B Flat head (0.6 mm x 3.5 mm) AWG26 to AWG16 (0.14 to 1.5 mm 2 ) 7 mm 2.51 mm (W) x 1.76 mm (H) C Flat head (0.4 mm x 2.5 mm) AWG28 to AWG16 (0.08 to 1.5 mm 2 ) 7 mm 1.72 mm (W) x 2.7 mm (H) * Manufacturer of post terminals: Phoenix Contact Inc. Refer to Table 2.6. Table 2.6 Recommended Post Terminals Type Screw size With insulated collar Without insulated collar AWG24 (0.25mm 2 ) AI0.25-6BU - AWG22 (0.34mm 2 ) AI0.34-6TQ A AWG20 (0.5mm 2 ) AI0.5-6WH A0.5-6 AWG18 (0.75mm 2 ) AI0.75-6GY A AWG16 (1.25mm 2 ) AI1.5-6BK A mm Head thickness: 0.6 mm Screwdriver head style 2-8

23 2.3.4 Recommended wire sizes Table 2.7 lists the recommended wire sizes. The recommended wire sizes for the main circuits are examples of using HIV single wire (for 75 C) at an ambient temperature of 50 C. Power supply voltage Three-phase 400 V Applicable motor rating (kw) Inverter type Table 2.7 Main circuit power input (L1/R, L2/S, L3/T) w/ DCR w/ DCR Recommended Wire Sizes Recommended wire size (mm 2 ) *1 Main circuit Grounding [ G] 5.5 FRN5.5LM1S FRN7.5LM1S FRN11LM1S FRN15LM1S Inverter output [U, V, W] 18.5 FRN18.5LM1S FRN22LM1S-4 8 Auxiliary Power Input (Ctrl. cct.) [R0, T0] Braking resistor [DB] DCR [P1, P (+)] DCR: DC reactor *1 Use the terminal crimp with an insulation sheath or with processing by the insulation tube. Use the wire of 75 C, 600 V, HIV-insulated. This selection assumes the inverter is used in ambient temperature at 50 C. Note A box ( ) in the above table replaces C, E or A depending on the shipping destination Control circuit

24 2.3.5 Wiring precautions Follow the rules below when performing wiring for the inverter. (1) Make sure that the source voltage is within the rated voltage range specified on the nameplate. (2) Be sure to connect the three-phase power wires to the main circuit power input terminals L1/R, L2/S and L3/T of the inverter. If the power wires are connected to other terminals, the inverter will be damaged when the power is turned on. (3) Always connect the grounding terminal to prevent electric shock, fire or other disasters and to reduce electric noise. (4) Use crimp terminals covered with insulated sleeves for the main circuit terminal wiring to ensure a reliable connection. (5) Keep the power supply wiring (primary circuit) and motor wiring (secondary circuit) of the main circuit, and control circuit wiring as far away as possible from each other. When wiring the inverter to the power source, insert a recommended molded case circuit breaker (MCCB) or earth leakage circuit breaker (ELCB) (with overcurrent protection) in the path of each pair of power lines to inverters. Use the devices recommended ones within the related current range. Use wires in the specified size. Tighten terminals with recommended torque. Otherwise, fire could occur. Use a multi-core power cable (3- or 4-wires) to wire the inverter with a motor. Do not connect a surge killer to the inverter's output circuit. Doing so could cause fire. According to the input power series install FRENIC-Lift in compliance with local regulations. Otherwise, electric shock or fire could occur. Qualified electricians should carry out wiring. Be sure to perform wiring after turning the power off. Otherwise, electric shock could occur. Be sure to perform wiring after installing the inverter. Otherwise, electric shock or injuries could occur. Ensure that the number of input phases and the rated voltage of the product match the number of phases and the voltage of the AC power supply to which the product is to be connected. Do not connect the power source wires to output terminals (U, V, and W). Doing so could cause fire or an accident Wiring for main circuit terminals and grounding terminals Table 2.8 shows the main circuit power terminals and grounding terminals. Table 2.8 Symbols, Names and Functions of the Main Circuit Power Terminals Symbol Name Functions L1/R, L2/S, L3/T Main power inputs Connect the 3-phase input power lines. U, V, W Inverter outputs Connect a 3-phase motor. R0, T0 Auxiliary power input for the control circuit For a backup of the control circuit power supply, connect AC power lines same as that of the main power input. P1, P(+) DC reactor connection Connect a DC reactor (DCR) for improving power factor. P(+), N(-) DC link bus Connect an optional regenerative converter or the equivalent. P(+), DB Braking resistor connection Connect a braking resistor. G 2 Grounding for inverter and motor Grounding terminals for the inverter s chassis (or case) and motor. Earth one of the terminals and connect the grounding terminal of the motor. Inverters provide a pair of grounding terminals that function equivalently. 2-10

25 Follow the procedure below for wiring and configuration of the inverter. Figure 2.8 illustrates the wiring procedure with peripheral equipment. Wiring procedure Grounding terminals ( G) Inverter output terminals (U, V, W, and G) DC reactor connection terminals (P1 and P(+))* DC link bus terminals (P(+) and N(-))* Main circuit power input terminals (L1/R, L2/S and L3/T) Auxiliary power input terminals for the control circuit (R0 and T0)* Braking resistor connection terminals (P(+) and DB) * Perform wiring as necessary Power supply Molded case circuit breaker (MCCB) or earth leakage circuit breaker (ELCB) with over current protection CAUTION: Do not connect more than 2 wires to terminal P(+). Regenerative converter Magnetic contactor Motor Braking resistor DC reactor (DCR) Figure 2.8 Wiring Procedure for Peripheral Equipment 2-11

26 Grounding terminals ( G) Be sure to ground either of the two grounding terminals for safety and noise reduction. Install FRENIC-Lift in compliance with the local regulations, Described below for an example, a procedure shows an installation of the inverter in compliance with regulations in Japan. E.g. grounding terminals should be grounded as follows: 1) Connect the grounding terminal of the 400 V series of inverters to a ground electrode on which class C grounding work has been completed, with conformity to the Electric Facility Technical Standard. 2) Connect a thick grounding wire with a large surface area and which meets the grounding resistance requirements listed in Table 2.9. Keep the wiring length as short as possible. Table 2.9 Grounding Stipulated in the Electric Facility Technical Standard Supply voltage Grounding work class Grounding resistance 3-phase 400 V Class C 10 Ω or less Inverter output terminals, U, V, W and grounding terminals ( G) Inverter s output terminals should be connected as follows: 1) Connect the three wires of the 3-phase motor to terminals U, V, and W, aligning phases each other. 2) Connect the secondary grounding wire to the grounding terminal ( G). The wiring length between the inverter and motor should not exceed 50 m, when they are connected directly. Do not connect a power factor correcting capacitor or surge absorber to the inverter s output lines (secondary circuit). If the wiring length is long, the stray capacitance between the wires will increase, resulting in an outflow of the leakage current. It will activate the overcurrent protection, increase the leakage current, or will not assure the accuracy of the current display. In the worst case, the inverter could be damaged. Do not drive two or more motors by single inverter. Driving 400 V series motor If a thermal relay is installed in the path between the inverter and the motor to protect the motor from overheating, the thermal relay may malfunction even with a wiring length shorter than 50 m. In this situation, lower the carrier frequency (Function code F26: Motor sound (Carrier frequency)). When a PWM-type inverter is driving a motor surge voltage that is generated by switching the inverter component may be superimposed on the inverter output and may be applied to the motor terminals. Particularly if the wiring length is long, the surge voltage may deteriorate the insulation resistance of the motor. Consider any of the following measures. - Use a motor with insulation that withstands the surge voltage. - Minimize the wiring length between the inverter and motor. DC reactor terminals, P1 and P (+) 1) Remove the short bar from terminals P1 and P(+). 2) Connect a DC reactor (option) to terminals P1 and P(+). The wiring length should be 10 m or below. Do not remove the short bar installed across P1 and P(+) terminals if a DC reactor is not to be used. 2-12

27 DC link bus terminals, P (+) and N (-) These are provided for the DC link bus powered system. Connect these terminals with terminals P(+) and N (-) of an optional regenerative converter or the equivalent. Consult your Fuji Electric representative if these terminals are to be used. Main circuit power input terminals, L1/R, L2/S, and L3/T (three-phase input) 1) For safety, make sure that the molded case circuit breaker (MCCB) or magnetic contactor (MC) is turned off before wiring the main circuit power input terminals. 2) Connect the main circuit power supply wires (L1/R, L2/S and L3/T) to the input terminals of the inverter via an MCCB or residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB)*, and MC if necessary. It is not necessary to align phases of the power supply wires and the input terminals of the inverter with each other. * With overcurrent protection It is recommended that a magnetic contactor be inserted that can be manually activated. This is to allow you to disconnect the inverter from the power supply in an emergency (e.g., when the protective function is activated) so as to prevent a failure or accident from causing the secondary problems. Auxiliary power input terminals R0 and T0 for the control circuit In general, the inverter will run normally without power supplied to the auxiliary power input for the control circuit. However, if you share the input power for the control circuit with that for the main circuit, you would be lost when, in the event of an error or alarm, you turn OFF the magnetic contactor between the inverter and the commercial power supply. If the magnetic contactor is turned OFF, the input power to the control circuit is shut OFF, causing the alarm signals (30A/B/C) to be lost and the display on the keypad to disappear. To secure input power to the control circuit at all times, supply the power from the primary side of the magnetic contactor to control power auxiliary input terminals R0 and T0. The method of connecting auxiliary power input terminals for the control circuit refer to Section "Setting up slide switches." Braking resistor connection terminals, P(+) and DB 1) Connect terminals P and DB of an external braking resistor to terminals P(+) and DB on the main circuit terminal block. (For the braking resistor built-in type, refer to the next page.) 2) When using an external braking resistor, arrange the inverter and braking resistor to keep the wiring length to 5 m or less and twist the two wires or route them together in parallel. Never insert a braking resistor between terminals P(+) and N(-), P1 and N(-), P(+) and P1, DB and N(-), or P1 and DB. Doing so could cause fire. 2-13

28 2.3.7 Wiring for control circuit terminals In general, sheaths and covers of the control signal cables and wires are not specifically designed to withstand a high electric field (i.e., reinforced insulation is not applied). Therefore, if a control signal cable or wire comes into direct contact with a live conductor of the main circuit, the insulation of the sheath or the cover might break down, which would expose the signal wire to a high voltage of the main circuit. Make sure that the control signal cables and wires will not come into contact with live conductors of the main circuit. Failure to observe these precautions could cause electric shock and/or an accident. Noise may be emitted from the inverter, motor and wires. Implement appropriate measure to prevent the nearby sensors and devices from malfunctioning due to such noise. An accident could occur. Table 2.10 lists the symbols, names and functions of the control circuit terminals. The wiring to the control circuit terminals differs depending upon the setting of the function codes, which reflects the use of the inverter. 2-14

29 Table 2.10 Symbols, Names and Functions of the Control Circuit Terminals Classification Symbol Name Functions [12] Voltage input (1) The reference speed (frequency) follows the input voltage level on terminal [12]. - 0 to ±10 VDC/0 to ±100 (%) - Definition of 100%: Maximum speed (F03) (2) The reference torque bias follows the input voltage level on terminal [12]. - 0 to ±10 VDC/0 to ±100 (%) - Definition of the 100% torque bias: Rated output torque of the motor (3) The reference torque current follows the input voltage level on terminal [12]. - 0 to ±10 VDC/0 to ±100 (%) - Definition of 100% torque current: Rated overcurrent of the inverter [C1] Current input (1) The reference speed (frequency) follows the input current level on terminal [C1] to +20 ma DC/0 to 100 (%) - Definition of 100%: Maximum speed (F03) (2) The reference torque bias follows the input current level on terminal [C1] to +20 ma DC/0 to 100 (%) - Definition of the 100% torque bias: Rated output torque of the motor (3) The reference torque current follows the input current level on terminal [C1] to +20 ma DC/0 to 100 (%) - Definition of 100% torque current: Rated overcurrent of the inverter * Input impedance: 250 Ω * Allowable input current is +30 ma DC. If the input current exceeds +20 ma DC, the inverter will limit it at +20 ma DC. Analog input [V2] Voltage input (1) The reference speed (frequency) follows the input voltage level on terminal [V2]. - 0 to ±10 VDC/0 to ±100 (%) - Definition of 100%: Maximum speed (F03) (2) The reference torque bias follows the input voltage level on terminal [V2]. - 0 to ±10 VDC/0 to ±100 (%) - Definition of the 100% torque bias: Rated output torque of the motor (3) The reference torque current follows the input voltage level on terminal [V2]. - 0 to ±10 VDC/0 to ±100 (%) - Definition of 100% torque current: Rated overcurrent of the inverter (4) This terminal is also used to connect a PTC (Positive Temperature Coefficient) thermistor to protect the motor from an overheat failure. To do so, switch SW4 on the control PCB to PTC side. Figure shown at the right illustrates the internal circuit diagram where the slide switch SW4 (switching the input of terminal [V2] between V2 and PTC) selects PTC. For details of SW4 refer to Section Setting up slide switches. In this case, you must change data of the function code H26. Figure 2.9 Internal Circuit Diagram (SW4 Selecting PTC) * Input impedance: 22 kω * Allowable input voltage is +15 VDC. If the input voltage exceeds +10 VDC, however, the inverter will limit it at +10 VDC. 2-15